Methods for Fabricating Lenses at the End of Optical Fibers in the Far Field of the Fiber Aperture

ABSTRACT

A microlens is affixed in the far field of an optical fiber to spatially transform a beam either entering or exiting the fiber. In a first embodiment, a droplet of photo polymer is placed on the end of an optical fiber and the fiber is spun to create an artificial gravity. The droplet is cured by UV radiation during the spinning. In a second embodiment, nanoparticles are mixed into the droplet to increase the refractive index of the photo polymer. A third embodiment employs artificial gravity to attach a microsphere to the end of the optical fiber. A fourth embodiment chemically treats the surface of the microsphere so that the requirement of artificial gravity is either reduced or eliminated. In a fifth embodiment the droplet is cured under equlibrium or nonequilibrium conditions to obtain different final shapes for the lenslet. A sixth embodiment discloses fabrication of microlens arrays.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of pending application Ser. No.10/369,993, entitled “Method for Fabricating Lenses at the End ofOptical Fibers in the Far Field of the Fiber Aperture,” filed on Feb.20, 2003, the contents of which are incorporated herein by reference,which claims the benefit of U.S. Provisional Patent Application60/358,143, of the same title by the same inventor, filed Feb. 20, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates, generally, to the fabrication of microlensesattached to the end of optical fibers or small cylindrical rods ingeneral. The purpose of the microlens is to focus light entering orleaving the fiber or mini-rod.

2. Description of the Prior Art

Lenses are used in fiber optics for coupling a signal propagatingthrough an optical fiber into preselected photonic components. Anoptical beam exiting a fiber must be focused or collimated to facilitateits coupling to a preselected photonic component.

External lenses, one of which is known as the GRIN lens, are in currentuse.

Attempts, with varying degrees of success, have been made to improveupon such external lenses by positioning a lensing element at the distalend of the fiber, in the near field of the fiber aperture. However sucha lens, at best, can only focus the output beam. Moreover, such lenseswould be expensive to produce on a commercial scale.

One prior art lens provides a non-focusing lens in the far field; thedivergence of the beam is merely reduced.

What is needed, then, is an inexpensive means for better focusing orcollimating a light beam exiting an optical fiber. More particularly, afocusing lenslet is needed at the distal end of an optical fiber in thefar field of the fiber aperture.

However, in view of the prior art considered as a whole at the time thepresent invention was made, it was not obvious to those of ordinaryskill in the pertinent art how the identified need could be fulfilled.

SUMMARY OF THE INVENTION

The long-standing but heretofore unfulfilled need for a method forfabricating lenses at the end of optical fibers in the far field of thefiber aperture is now met by a new, useful, and nonobvious method thatincludes the steps of selecting a lens material from a group of lensmaterials having a large refractive index, high transparency, lowshrinkage upon curing, good thermal stability, and ease of curing whilecentrifuged. A droplet of said lens material is applied to a preselectedend of the optical fiber, followed by application of a predeterminedartificial gravitational acceleration by spinning the optical fiber anddroplet in a centrifuge. The lens material is cured by a suitable meansas the optical fiber is spinning.

In a second embodiment, nanoparticles of a preselected transparentmaterial having a high refractive index are incorporated into the lensmaterial, thereby creating a composite lens material having an increasedrefractive index and providing a gradient in the refractive index toenhance the focusing capability of the composite lens material. Thenanoparticles are incorporated into the lens material prior to theapplication of artificial gravity.

In a third embodiment, a microsphere is introduced into the lensmaterial prior to application of the artificial gravitationalacceleration.

The novel method of attaching a microsphere to a preselected end of anoptical fiber at a preselected distance from said preselected endincludes the steps of selecting an optical cement having a preselectedsurface tension and a preselected density. A microsphere having adensity greater than the preselected density of the optical cement isthen selected. A droplet of the optical cement is applied to thepreselected end of the optical fiber and the optical fiber is positionedin a vertical plane so that the optical cement depends from a lowermostend of the optical fiber and a microsphere is introduced into theoptical cement. At least a portion of the microsphere but less than ahemisphere of the microsphere protrudes from the optical cement. Theoptical fiber and droplet are then mounted on a rotatable disc and anartificial gravitational acceleration is applied to the optical fiberand droplet along a longitudinal axis of symmetry of the optical fiberby spinning the disc about its rotational axis with the dropletpositioned radially outward of the optical fiber. The optical cement iscured while the disc is spinning. In this way, the microsphere isattached to the preselected end of the optical fiber at a preselecteddistance from said preselected end.

A top wall of the disc has a predetermined slope so that a center of thedisc is elevated with respect to the peripheral edge of the disc. Thepredetermined slope is an angle equal to the arctan of the ratio of thegravitational acceleration of earth to the artificial gravitationalacceleration produced by the spinning.

In a fourth embodiment, the surface of the microsphere is chemicallytreated to produce a preselected contact angle with respect to theoptical cement so that the step of applying the artificial gravitationalacceleration is eliminated.

A fifth embodiment includes a method for fabrication of lenslets inartificial gravity under nonequilibrium conditions. A droplet isdeposited on an optical fiber and may be partially cured prior tospinning said droplet to increase the starting viscosity of the dropletto a predetermined high value.

More particularly, the droplet is spun for a predetermined amount oftime with a predetermined time profile of the rotational speed. The timerequired for the droplet to change its shape noticeably at any momentduring its evolution history from rest to a predetermined terminalrotational speed is long compared to its curing time. Moreover, theshape of the droplet is determined by the predetermined amount of timeand the predetermined time profile of the rotational speed.

In a first example of the fifth embodiment, a weak UV curing source isemployed so that the curing time of the droplet is comparable to thetotal spin time. The viscosity and surface tension coefficient of thedroplet varies with time as curing proceeds. The evolution of thedroplet ceases when a sufficiently high viscosity is reached. The use ofa weak UV curing source provides lenslet shapes that are different fromthose obtainable with a strong UV curing source.

In a second example of the fifth embodiment, the intensity of the weakUV curing source is varied with time. In a third example, the weakradiation is followed by a short intense pulse to instantaneouslysolidify the photopolymer at a preselected droplet shape. This providesstill further lenslet shapes not otherwise obtainable.

Microlens arrays are fabricated in a sixth embodiment. Apreviously-treated substrate is selected to produce an array of circularmesas and a plurality of photopolymer droplets is applied to the top ofeach circular mesa. The droplets are subjected to artificial gravity andcured by UV radiation under equilibrium or non-equilibrium conditions.

A novel method for forming an array of microlenses under artificialgravity includes the steps of providing a substrate having a pluralityof circular mesas formed therein and depositing a photopolymer dropletupon each of the mesas. A rotationally-mounted disc is adapted forrotation about a central axis of rotation. The disc includes a top wallhaving a first predetermined diameter, a bottom wall having a secondpredetermined diameter less than the first predetermined diameter, and asidewall interconnecting the top and bottom walls to one another. Thesidewall presents a wedge-shaped profile when viewed in side elevation.An angle a is defined as the angle between the plane of the top wall andthe plane of the sidewall.

A substrate is attached to the sidewall and each substrate is coveredwith a housing that includes a UV-transparent window means formedtherein. The disc is positioned within a rotor housing that isconcentrically mounted with respect to the central axis of rotation ofthe disc. A plurality of UV light sources is positioned incircumferential spacing around an inside wall of the rotor housing sothat a uniform light intensity impinges upon each photopolymer dropletregardless of its instantaneous position. The disc is rotated about thecentral axis with a predetermined time profile of the rotational speedfor a predetermined amount of time.

When the photopolymer droplet is subjected to equilibrium curing, thesidewall is angled relative to a plane perpendicular to the central axisof rotation at an angle the tangent of which is determined by the ratioof the artificial gravitational acceleration created by the rotation ofthe disc at the terminal rotational speed of the disc to the earth'sgravitational acceleration.

When the photopolymer droplet is subjected to non-equilibrium curing,the sidewall is angled relative to a plane perpendicular to the centralaxis of rotation at an angle the tangent of which is determined by theratio of the artificial gravitational acceleration created by saidrotation of the disc at the terminal rotational speed of the disc, theartificial gravitational acceleration corresponding to a rotationalspeed at which curing is essentially complete, to the earth'sgravitational acceleration.

The novel apparatus for forming an array of microlenses under artificialgravity includes a substrate having a plurality of circular mesas formedtherein. A photopolymer droplet is deposited atop each of said circularmesas. The novel apparatus further includes a rotatably mounted discadapted for rotation about a central axis of rotation. The disc has atop wall of first predetermined diameter, a bottom wall of secondpredetermined diameter less than the first predetermined diameter, and asidewall interconnecting the top and bottom walls to one another. Thesidewall presents a wedge-shaped profile when viewed in side elevation.A substrate is attached to the sidewall. A rotor housing is mountedconcentrically with respect to the central axis of rotation of the disc.A plurality of UV light sources are positioned in circumferentialspacing around an inside wall of the rotor housing so that a uniformlight intensity impinges upon each photopolymer droplet regardless ofits instantaneous position.

No housing and hence no window means formed therein is required when avacuum is provided between the inside wall of the rotor housing and thesidewall of the disc. The disc is rotated about the central axis with apredetermined time profile of the rotational speed for a predeterminedamount of time.

An important object of this invention is to provide reliable methods forattaching a microlens to an optical fiber in the far field of theoptical fiber.

A more specific object is to advance the art of optical fibermicrolenses by disclosing a method for forming a microlens by attachinga droplet of a suitable lens material to an optical fiber and spinningthe optical fiber and droplet in a centrifuge.

Additional important object includes advancing the art by incorporatingnanoparticles into the lens material prior to the application ofartificial gravity.

Still another object is to provide a method for incorporating amicrosphere into the lens material at a distance from the optical fiberwith the application of artificial gravity.

Yet another object is to provide a method for incorporating amicrosphere into the lens material and forming a microlens withoutsubjecting the optical fiber and lens material to artificial gravity.

Another object is to provide a method for fabrication of lenslets inartificial gravity under nonequilibrium conditions.

Another object is to provide a method for forming an array ofmicrolenses under artificial gravity.

These and other important objects, advantages, and features of theinvention will become clear as this description proceeds.

The invention accordingly comprises the features of construction,combination of elements, and arrangement of parts that will beexemplified in the description set forth hereinafter and the scope ofthe invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be made to the following detailed description, taken inconnection with the accompanying drawings, in which:

FIG. 1 is a diagrammatic view of a drop of liquid depending from anoptical fiber;

FIG. 2 is a diagrammatic view depicting the focusing of a thick lens;

FIG. 3 is a side elevational, diagrammatic view of a spinning platform;

FIG. 4 is a diagrammatic view of a microlens with a graded refractiveindex;

FIG. 5 is a diagrammatic view of a liquid droplet containing amicrosphere depending from a fiber;

FIG. 6A is diagrammatic view of a liquid cement droplet containing amicrosphere depending from a fiber;

FIG. 6B is an enlarged view of the microsphere depicted in FIG. 6A;

FIG. 7A is a top plan view of a substrate having an array of circularmesas;

FIG. 7B is a side elevational view thereof;

FIG. 7C is a side elevational view of said substrate after droplets of aphotopolymer are applied to the top of said mesas;

FIG. 8 is a top plan view of an apparatus for forming a microlens array;

FIG. 8A is an enlarged, detailed view of the circled area denoted 8A inFIG. 8;

FIG. 9 is a side elevational view of a spinning disc that forms a partof the apparatus for making a microlens array; and

FIG. 9A is an enlarged, detailed view of the circled area denoted 9A inFIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In a first embodiment, the lens material is a droplet of photopolymer,thermoplastic, sol-gel, or the like and is applied to a preselected endof a rod or fiber. The lens material is selected from the group ofsuitable lens materials having a large refractive index, hightransparency, low shrinkage upon curing, good thermal stability, andease of curing while centrifuged. The optical fiber is cleaved at apreselected end and the coating of optical fiber is removed with astripping agent. The droplet is applied at the cleaved end and theoptical fiber and droplet are placed in an artificial gravitationalacceleration.

The shape of the liquid drop is found from Laplace's formula:$\begin{matrix}{{\frac{1}{R_{1}} + \frac{1}{R_{2}} + \frac{g\quad\rho\quad y}{\alpha}} = {{const}.}} & ( {{equation}\quad 1} )\end{matrix}$

where R₁ and R₂ are the principal radii of curvature, g is gravitationalacceleration, ρ is the density of the liquid, and a is the surfacetension coefficient for the liquid. When the capillary constant$a = \sqrt{\frac{2\alpha}{g\quad\rho}}$is much larger than the dimensions of the drop, the last term on theleft may be ignored. This holds for rods having a diameter of about 100μat the surface of the earth. The shape of the solid lens will be thesame as that of the liquid if negligible shrinkage occurs uponsolidification.

With the coordinates as depicted in FIG. 1, equation (1) becomes$\begin{matrix}{{\frac{y^{''}}{( {1 + ( y^{\prime} )^{2}} )^{\frac{3}{2}}} + \frac{y^{\prime}}{{x( {1 + ( y^{\prime} )^{2}} )}^{\frac{1}{2}}}} = \frac{2}{R_{0}}} & ( {{equation}\quad 2} )\end{matrix}$

Where R₀ is the radius of curvature at x=0.

The solution to equation 2 isy=R ₀ −√{square root over (R₀ ²−x²)}  (equation 3)

It is seen that when gravity is ignored, the drop is a sphere having aflattened top.

The focusing by a thick lens as shown in FIG. 2 is given by:$\begin{matrix}{{\frac{1}{S} + \frac{n}{S}} = \frac{n - 1}{R}} & ( {{equation}\quad 4} )\end{matrix}$

To achieve large focusing power (for a given n), R must be made smalland S′ large. The largest S′/S is achieved for S′>>r, in which case:S′/S≅n−2  (equation 5)

For a given S′, R can be made smaller by applying an artificialgravitational acceleration, (through spinning, e.g.) to increase g andhence decrease a. For a comparable to r, the shapes of the droplets havebeen given by Freud & Hawkins in the Journal of Physical Chemistry,volume 33, page 1217 (1929). For r/a=0.6 and S′/a=1.6, e.g., R/a=0.6.From equation (4), S=S′ for n=2.2. In contrast, the best focusing powerwithout artificial gravity would be S′/S=0.2 for the same n fromequation (5). For r=120μ, a=0.2 mm. This corresponds to g=200 g₀, andcan readily be achieved by spinning.

As depicted in FIG. 3, a platform is mounted for rotation about avertical axis. The optical fiber is aligned in radial relation to theaxis of rotation with the droplet positioned radially outwardly of theoptical fiber. The optical fiber is positioned so that the droplet and apredetermined extent of the optical fiber overhang a peripheral edge ofthe platform. A top wall of the platform is sloped at a predeterminedslope so that a center of the platform is elevated with respect to theperipheral edge of the platform. The predetermined slope is an angleequal to the arctan of the ratio of the gravitational acceleration ofearth to the artificial gravitational acceleration produced by thespinning. More precisely, the angle θ should be made to be equal totan⁻¹(g₀/g_(s)) where g_(s) is the artificial gravitational accelerationproduced by spinning.

The polymer-tipped rod or fiber is placed inside a small glass tube toshield the droplet from the deleterious effects of air currents as theplatform is spun about its axis of rotation. When the droplet hasreached equilibrium, a curing/drying source such as a UV lamp is turnedon. To achieve uniformity of curing, a polished aluminum platform isused to reflect the UV radiation so that the top and bottom sides of thedroplet receive approximately equal irradiation. This prevents hardeningof one part of the lenslet prior to hardening of another part and thusreduces unwanted distortion.

The spinning has the effect of elongating the droplet and making it morepointed. The result is a microlens in the far field that overcomes thelimitations of microlenses heretofore known.

In a second embodiment of the invention, the refractive index of thepolymer or sol-gel is increased by mixing in high refractive indexnanoparticles formed of a transparent material such as Ti₂ O₃. This alsoenables producing a microlens with a graded refractive index along theoptical axis through centrifugation as depicted in FIG. 4.

Solid line AB indicates a bent ray as a result of the graded index, anddashed line AC is a straight line the ray would follow without thegradient.

Positioning Of Microsphere At End Of Optical Fiber By Artificial Gravity

In a third embodiment, a microsphere is attached to the end of anoptical fiber by using an optical cement for the purpose of focusing thelight coming out of the fiber. The focusing properties of themicrosphere depend on the thickness of the cement in between. The noveltechnique of this invention allows the controlled positioning of themicrosphere by applying an artificial gravitational acceleration to thefiber/microsphere assembly before the cement is cured.

When a fiber tipped with a liquid containing a microsphere is heldvertically with the droplet hanging at the bottom, the microsphereprotrudes out of the liquid if it has a density greater than that of theliquid, as depicted in FIG. 5. The extent of protrusion depends upon itssize and its surface interaction with the liquid, the radius of thefiber, the surface tension of the liquid, etc.

By balancing the “weight” of the microsphere with the buoyant force ofthe liquid and the atmosphere outside, to have the solid/liquid/gasintersection make an angle α with the “horizontal” (FIG. 5), theartificial gravitational acceleration needed is given by:$g = \frac{{6\quad\gamma\quad\cos\quad{\alpha( {\alpha + \theta_{c}} )}} - {3r\quad\Delta\quad{P( {1 - {\sin^{2}\alpha}} )}}}{{4r^{2}\rho^{\prime}} - {r^{2}{\rho( {2 + {3\sin\quad\alpha} - {\sin^{3}\alpha}} )}}}$

where γ is the surface tension of the liquid. θ_(c) is the contact angleof the liquid on the microsphere, r is the radius of the microsphere, ρand ρ′ are the densities of the liquid and the microsphere, and Δp isthe difference in pressure between the liquid at the bottom and theoutside atmosphere (p−p in FIG. 5).

For α=0, γ=40 dynes/cm, θ_(c)=30°, r=30μ, ΔP=γ/r, ρ=1.2 g/cm³, and ρ′=4g/cm³, g=700 g₀ where g₀ is the earth's gravitational acceleration. Thevolume of the liquid determines the gap between the microsphere and theend of the fiber.

The artificial gravity is created by placing the fiber on a rotatingdisk, with the fiber end pointing outwards. The microsphere is fixed inplace by applying UV/heat to cure the optical cement while the fiber isspun at the desired rotational speed. To correct for earth's gravitywhich will introduce some amount of asymmetry, the disc can be made tohave a slightly conical cross-sectional profile with a cone angle oftan⁻¹(g/g₀).

Distancing Microsphere From End Of Optical Fiber By Controlling ContactAngle

In a fourth embodiment, a microsphere is attached to the end of anoptical fiber at a distance from the fiber end if a suitable contactangle between the optical cement and the microsphere is selected asdepicted in FIGS. 6A and 6B.

For a cement drop>100 μm, forces due to liquid and air pressure can beignored. Accordingly, 2πrγ cos α cos(α+θ_(c))≅4/3πr³ρg

where γ is the surface tension of the cement and θ_(c) the contact anglebetween the cement and the microsphere. For r<50μ and typical values ofγ and ρ, the equation is satisfied for α+θ_(c)≅π/2. For small α, θ_(c)must be close to ninety degrees (90°), i.e., the cement must wet themicrosphere only slightly. When the microsphere is captured by thecement by contact, the fiber is held vertically as shown and cementUV/heat cured. If the contact angle between the selected cement and thenative surface of the sphere is not close to 90° to begin with, thelatter can be treated chemically to produce decreased wetting. Thismethod can either reduce or eliminate the need to apply artificialgravity.

Fabrication of Lenslets in Artificial Gravity under NonequilibriumConditions

In the above embodiments, curing of the droplet which is to become thelenslet is initiated when the artificial gravity generated by spinninghas reached a constant value and the droplet has had time to adjust toan equilibrium shape. Under these conditions the shape of the lensletfor a given base diameter and volume is completely determined by itsdensity, surface tension, and the magnitude of the artificialgravitational field. More precisely, where:

ρ=density of the liquid;

-   -   α=surface tension coefficient of liquid; and    -   g=artificial gravitational acceleration;

then the crucial parameter is the capillary constant defined by$a = \sqrt{\frac{2\alpha}{g\quad\rho}}$

When equilibrium has been reached at a given artificial gravitationalacceleration, i.e., when all flowing of the droplet has ceased, thefinal shape of the droplet is uniquely determined by its base diameter,its volume (or height), and the capillary constant a.

In this fifth embodiment the droplet is cured under nonequilibriumconditions to obtain different final shapes for the lenslet. Ahyperbolic shape is especially desirable because it providesdistortionless focusing for a collimated incident beam. In the followingexamples, the starting liquid is a photopolymer and the curing agent isultraviolet light, although other possibilities also exist (e.g.,thermoplastic with heat curing).

In a first example of the fifth embodiment, a droplet is deposited on anoptical fiber and may be partially cured before it is spun. Thisincreases the starting viscosity of the droplet to a sufficiently highvalue so that the time required for the droplet to change its shapenoticeably at any moment during its evolution history from rest to apredetermined terminal rotational speed is long compared to its curingtime. Accordingly, it becomes possible to obtain any of the intermediateshapes between the two times. The sequence of intermediate shapes itselfdepends on the predetermined time profile of the rotational speed.

In a second example of the fifth embodiment, a weak UV curing source isused so that the curing time is comparable to the total spin time. Thus,the viscosity and surface tension coefficient of the photopolymer varieswith time in addition to the rotational speed. The evolution of thedroplet ceases when a sufficiently high viscosity is reached. Lensletshapes different from those obtainable with the first example of thisfifth embodiment can be provided when the steps of this second exampleare followed.

In a third example of the fifth embodiment, the second method ismodified by programming the intensity of the weak UV curing source tovary with time. In particular, the weak radiation may be followed at theend by a short intense pulse to instantaneously solidify thephotopolymer at some desired droplet shape. This third example of thefifth embodiment thus produces lenslet shapes not possible with thefirst examples.

In view of this disclosure, it is now obvious to those of ordinary skillin this art that other variations are possible to produce lens-tippedoptical fibers in artificial gravity under nonequilibrium conditions.

In a sixth embodiment, the same basic principles are applied to thefabrication of microlens arrays. The process begins by selecting asubstrate that has been treated previously (e.g., lithographically) toproduce an array of circular mesas. FIGS. 7A and 7B provide top and sideviews, respectively, of such a substrate, denoted 10 as a whole.Droplets of photopolymer 12 (FIG. 7C) are applied to the top of mesas 14by microjetting or other suitable means.

The shape of each droplet 12 will always be spherical in normal gravityfor mesa diameters of less than approximately one millimeter (1 mm),regardless of the orientation of substrate 10. When used to focus a beamof light, such a shape will lead to spherical aberration, especiallywhen the thickness of the lens is a substantial fraction of its diameterat the base and the light beam fills a large portion of the availableaperture. This aberration is reduced by subjecting droplets 12 toartificial gravity prior to curing by UV radiation under eitherequilibrium or non-equilibrium conditions.

A preferred embodiment of an apparatus that forms an array ofmicrolenses under artificial gravity is depicted in FIGS. 8, 8A, 9, and9A. Substrates 10 with photopolymer droplets 12 are attached to spinningdisk 16 which is mounted for rotation as indicated by directional arrow15 about axis 17. Disc 16 is a many sided polygon with a wedged side asseen in side elevation or cross section, as shown in FIG. 9.

More particularly, disc 16 includes top wall 16 a of first predetermineddiameter, bottom wall 16 b of second predetermined diameter less thansaid first predetermined diameter, and sidewall 16 c interconnectingsaid top and bottom walls to one another, said sidewall presenting awedge-shaped profile when viewed in side elevation.

The wedge-shaped side eliminates the effect of the earth's gravitationalfield. As indicated in the detailed views of FIGS. 8A and 9A, eachsubstrate 10 is covered by a housing 20 which is fitted with a window 22transparent to the UV radiation required for curing. Housing 20eliminates any deleterious effect that might be caused by air turbulenceduring spinning. As depicted in FIG. 8, a plurality of UV light sources24 are circumferentially arranged around the inside of rotor housing 26in such a way that each array sees essentially a uniform light intensityregardless of its instantaneous position. Array housings 20 can beeliminated if a vacuum is provided in the space in which the arrays arespun.

In the case of equilibrium curing, wedge angle a (FIG. 9) should be made$\alpha = {\tan^{- 1}( \frac{g}{g_{0}} )}$

where g₀ is Earth's gravitational acceleration and g is the artificialgravitational acceleration at the terminal rotational speed. In the caseof non-equilibrium curing, g should correspond to the rotational speedat which curing is essentially complete.

It will thus be seen that the objects set forth above, and those madeapparent from the foregoing description, are efficiently attained. Sincecertain changes may be made in the above construction without departingfrom the scope of the invention, it is intended that all matterscontained in the foregoing description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention that, as amatter of language, might be said to fall therebetween.

Now that the invention has been described,

1. An apparatus for forming an array of microlenses under artificialgravity, comprising: a substrate having a plurality of circular mesasformed therein; a photopolymer droplet positioned atop each of saidcircular mesas; a rotatably mounted disc adapted for rotation about acentral axis of rotation; said disc having a top wall of firstpredetermined diameter, a bottom wall of second predetermined diameterless than said first predetermined diameter, and a sidewallinterconnecting said top and bottom walls to one another, said sidewallpresenting a wedge-shaped profile when viewed in side elevation; asubstrate secured to said sidewall; a rotor housing that isconcentrically mounted with respect to said central axis of rotation ofsaid disc disposed in encircling relation to said disc; a plurality ofUV light sources positioned in circumferential spacing around an insidewall of said rotor housing so that a uniform light intensity impingesupon each photopolymer droplet regardless of its instantaneous position;a housing covering each substrate; a UV-transparent window means formedin each housing; whereby rotation of said disc about said central axiswith a predetermined time profile of rotational speed for apredetermined amount of time forms said array of miocrolenses.
 2. Anapparatus for forming an array of microlenses under artificial gravity,comprising: a substrate having a plurality of circular mesas formedtherein; a photopolymer droplet positioned atop each of said circularmesas; a rotatably mounted disc adapted for rotation about a centralaxis of rotation; said disc having a top wall of first predetermineddiameter, a bottom wall of second predetermined diameter less than saidfirst predetermined diameter, and a sidewall interconnecting said topand bottom walls to one another, said sidewall presenting a wedge-shapedprofile when viewed in side elevation; a substrate secured to saidsidewall; a rotor housing that is concentrically mounted with respect tosaid central axis of rotation of said disc disposed in encirclingrelation to said disc; a plurality of UV light sources positioned incircumferential spacing around an inside wall of said rotor housing sothat a uniform light intensity impinges upon each photopolymer dropletregardless of its instantaneous position; and a vacuum between saidinside wall of said rotor housing and said sidewall of said disc;whereby rotation of said disc about said central axis with apredetermined time profile of rotational speed for a predeterminedamount of time forms said array of miocrolenses.